Method and apparatus for modular power distribution

ABSTRACT

A method and apparatus for modular power distribution includes an end module and at least one switching module having a switching module electrical power interface configured to electrically connect to at least one of the end module electrical power interface, to another switching module electrical power interface, or to at least one voltage converter module, and having at least one of a switching element, an input/output connector, a switching module communication interface, or a bus bar connector, wherein the modules are physically secured.

CROSS-REFERENCE TO RELATED APPLICATIONS

The present application claims the benefit of U.K. Patent ApplicationNo. 1603780.6, filed Mar. 4, 2016, which is incorporated by referenceherein in its entirety.

BACKGROUND OF THE INVENTION

Electrical power systems, such as those found in an aircraft powerdistribution system, employ power generating systems or power sources,such as generators, for generating electricity for powering electricalloads, such as loads in the systems and subsystems of an aircraft. Asthe electricity traverses electrical bus bars to deliver power frompower sources to electrical loads, power distribution nodes dispersedthroughout the power system ensure that power delivered to theelectrical loads meets the designed power criteria for the loads. Powerdistribution nodes can, for instance, further provide step-up orstep-down power conversion, direct current (DC) to alternating current(AC) power conversion or AC to DC power conversion, or switchingoperations to selectively enable or disable the delivery of power toparticular electrical loads, depending on, for example, available powerdistribution supply, criticality of electrical load functionality, oraircraft mode of operation, such as take-off, cruise, or groundoperations.

Typical power distribution nodes include one or more rack assemblies forincluding, for example, a number of electronic cards to provide for theaforementioned conversions or switching functions. The rack assembliesare not typically optimized to be contained within the smallestconfigurable installation volume, leading to rack assemblies larger thannecessary, and unused or underutilized components.

BRIEF DESCRIPTION ON THE INVENTION

In one aspect, the disclosure relates to a modular power distributionapparatus including a first end module and a second end module, at leastone of the first or second end modules having at least one of an endmodule communication interface, a power supply, or a processor, at leastone switching module having a switching module electrical powerinterface configured to electrically connect to another switching moduleelectrical power interface, and having at least one of a switchingelement, an input/output connector, a switching module communicationinterface, or a bus bar connector, and at least one voltage convertermodule having an electrical power interface configured to electricallyconnect to at least one switching module electrical power interface,another voltage converter module electrical power interface, or a busbar connector. At least a subset of the first end module, the second endmodule, the at least one switching module, and the at least one voltageconverter module have an attachment interface configured to physicallysecure the at least one switching module and the at least one voltageconverter module to and between the first end module and the second endmodule, or to another switching module or voltage converter module, withthe at least one of the first or second end modules communicativelyconnected to the at least one switching module, and at least one of theswitching element, input/output connector, the switching modulecommunication interface, or the bus bar connector being selectivelyconnected to at least one of the first end module, the second endmodule, another switching module, or the voltage converter module.

In another aspect, the disclosure relates to a modular powerdistribution apparatus including at least one first end module and atleast one second end module, at least one of the first and second endmodules having at least one of an end module communication interface ora processor, at least one switching module having a switching moduleelectrical power interface configured to electrically connect to atleast another switching module electrical power interface, and having atleast one of a switching element, an input/output connector, a switchingmodule communication interface, or a bus bar connector, and at least onevoltage converter module having a voltage converter module electricalpower interface to connect to at least another voltage converter powerinterface, at least one switching module electrical power interface, ora bus bar connector. The first end module, the second end module, the atleast one switching module, and the at least one voltage convertermodule have an attachment interface configured to physically secure theat least one switching module to at least one of the first or second endmodules, between the first end module and the second end module, or toanother switching module or voltage converter module, in one or moreaxes.

In yet another aspect, the disclosure relates to a method ofdistributing power in an aircraft, the method including connecting atleast one first end module having at least one of an end modulecommunication interface, a power supply, or a processor to a at leastone switching module having a switching module electrical powerinterface and having at least one of a switching element, aninput/output connector, a switching module communication interface, or abus bar connector by connecting the end module communication interfaceto the switching module communication interface, connecting the at leastone voltage converter module to the at least one other switching modulehaving a voltage converter module electrical power interface byconnecting the switching electrical power interface to the voltageconverter module electrical power interface, connecting at least onesecond end module to the at least one voltage converter module or atleast one other switching module, physically attaching in one or twoaxes the at least one first end module to the at least one switchingmodule, and the at least one switching module to the at least onevoltage converter module, and the at least one voltage converter moduleor at least one other switching module to the at least one second endmodule by way of an attachment interface, and connecting the at leastone switching module to a power source.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a top down schematic view of the aircraft and powerdistribution system of an aircraft in accordance with various aspectsdescribed herein.

FIG. 2 is a schematic view of a power distribution node of the aircraftand power distribution system of FIG. 1, in accordance with variousaspects described herein.

FIG. 3 is an exploded isometric view of a power distribution apparatusfor a power distribution node in accordance with various aspectsdescribed herein.

FIG. 4 is an isometric view of the assembled power distributionapparatus of FIG. 3, in accordance with various aspects describedherein.

FIG. 5 is a schematic view of another power distribution node, inaccordance with various aspects described herein.

FIG. 6 is an isometric view of the assembled power distributionapparatus of FIG. 5, in accordance with various aspects describedherein.

FIG. 7 is an example a flow chart diagram of a method of distributingpower in an aircraft in accordance with various aspects describedherein.

DETAILED DESCRIPTION

The described aspects of the present disclosure are directed to a methodand apparatus associated with a modular power distribution apparatus.One example environment where such a method and apparatus can be usedincludes, but is not limited to, a power distribution system for anaircraft. While this description is primarily directed toward a powerdistribution system for an aircraft, it is also applicable to anyenvironment using a nodal-based power distribution system where inputpower is received, acted upon (if necessary), e.g., converted ormodified, and distributed to one or more electrical loads.

While “a set of” various elements will be described, it will beunderstood that “a set” can include any number of the respectiveelements, including only one element. The use of the terms “proximal” or“proximate” to an element refers to a component being relatively closerto the element as compared to another component. Connection references(e.g., attached, coupled, connected, and joined) are to be construedbroadly and can include intermediate members between a collection ofelements and relative movement between elements unless otherwiseindicated. As such, connection references do not necessarily infer thattwo elements are directly connected and in fixed relation to each other.In non-limiting examples, connections or disconnections can beselectively configured to provide, enable, disable, or the like, anelectrical connection between respective elements. Non-limiting examplepower distribution bus connections or disconnections can be enabled oroperated by way of switching, bus tie logic, or any other connectorsconfigured to enable or disable the energizing of electrical loadsdownstream of the bus. The exemplary drawings are for purposes ofillustration only and the dimensions, positions, order and relativesizes reflected in the drawings attached hereto can vary.

As illustrated in FIG. 1, an aircraft 10 is shown having at least onegas turbine engine, shown as a left engine system 12 and a right enginesystem 14. Alternatively, the power system can have fewer or additionalengine systems. The left and right engine systems 12, 14 can besubstantially identical, and can further include at least one powersource, such as an electric machine or a generator 18. The aircraft isshown further having a set of power-consuming components, or electricalloads 20, such as for instance, an actuator load, flight critical loads,and non-flight critical loads. The electrical loads 20 are electricallycoupled with at least one of the generators 18 via a power distributionsystem including, for instance, power transmission lines 22 or bus bars,and power distribution nodes 16. It will be understood that theillustrated aspect of the disclosure of FIG. 1 is only one non-limitingexample of a power distribution system, and many other possible aspectsand configurations in addition to that shown are contemplated by thepresent disclosure. Furthermore, the number of, and placement of, thevarious components depicted in FIG. 1 are also non-limiting examples ofaspects associated with the disclosure.

In the aircraft 10, the operating left and right engine systems 12, 14provide mechanical energy which can be extracted, typically via a spool,to provide a driving force for the generator 18. The generator 18, inturn, generates power, such as AC or DC power, and provides thegenerated power to the transmission lines 22, which delivers the powerto the power distribution nodes 16, positioned throughout the aircraft10. The power distribution nodes 16 receive the AC or DC power via thetransmission lines 22, and can provide switching, power conversion, ordistribution management functions, as needed, in order to provide thedesired electrical power to the electrical loads 20 for load operations.

Example power distribution management functions can include, but are notlimited to, selectively enabling or disabling the delivery of power toparticular electrical loads 20, depending on, for example, availablepower distribution supply, criticality of electrical load 20functionality, or aircraft mode of operation, such as take-off, cruise,or ground operations. The power distribution nodes 16 are shownselectively coupled with a single electrical load 20 for ease ofillustration and understanding. Aspects of the disclosure can includepower distribution nodes 16 that are selectively coupled with a set ofelectrical loads 20, wherein a power distribution node 16 canselectively enable or disable the delivery of power to individual or asubset of the electrical loads 20, as described herein. Additionally,all or a subset of the power distribution nodes 16 can be furtherinterconnected (not shown) in order to provide redundant power supply inthe event of malfunction or failure of a single node 16.

Additional management functions can be included. Furthermore, additionalpower sources for providing power to the electrical loads 20, such asemergency power sources, ram air turbine systems, starter/generators, orbatteries, can be included, and can substitute for the power source. Itwill be understood that while one aspect of the disclosure is shown inan aircraft environment, the disclosure is not so limited and hasgeneral application to electrical power systems in non-aircraftapplications, such as other mobile applications and non-mobileindustrial, commercial, and residential applications.

FIG. 2 schematically illustrates a power distribution node 16 of FIG. 1.As shown, the power distribution node 16 can include a modular powerdistribution apparatus 24 or modular power distribution assembly havinga set of switching modules 26 between one or more end modules 28. In theillustrated aspect, the power distribution node 16 includes a first endmodule 28, shown as a common control module 30, and an opposing secondend module 28, which can include an end plate 32 or physical cover. Thecommon control module can further include a set of subcomponents orsubsystems including, but not limited to a communication interfacecontroller 34, a processor 38, and memory 40.

In one non-limiting aspect of the power distribution node 16, the set ofswitching modules 26 can include a first switching module 42, a secondswitching module 44, a third switching module 46, a fourth switchingmodule 48, a fifth switching module 50, a sixth switching module 52, anda seventh switching module 54. Aspects of the disclosure can be includedwherein each in the set of switching modules 26 are substantially alike,that is, of similar construction and composition. Alternatively, the setof switching modules 26 can include at least two subsets of similarconstructions and compositions. The similarity of the set of switchingmodules 26 can enable faster, easier, or more efficient maintenanceoperations.

The individual switching modules 42, 44, 46, 48, 50, 52, 54 are shown ina common physical alignment, for example, where the longitudinaldirection of the set of switching modules 26 is parallel to adjacentswitching modules 26, or wherein the set of switching modules 26 isarranged serially, or in series. Each module 42, 44, 46, 48, 50, 52, 54of the set of switching modules 26 can include at least one switchingmodule electrical power interface 56, at least one input/outputconnector 58, a switching module communication interface 60, and aswitching element 62.

In one non-limiting example, each module 42, 44, 46, 48, 50, 52, 54 caninclude two electrical power interfaces 56 that are schematicallyillustrated at opposing longitudinal ends of the module 42, 44, 46, 48,50, 52, 54. Likewise, in another non-limiting example, each module 42,44, 46, 48, 50, 52, 54 can include two input/output connectors 58 thatare schematically illustrated at opposing longitudinal ends of themodule 42, 44, 46, 48, 50, 52, 54. The switching module communicationinterface 60 of each respective module 42, 44, 46, 48, 50, 52, 54 cancollectively define a common control interface 60, which can be furthercommunicatively coupled with the communication interface controller 34of the common control module 30.

At least a subset of the input/output connectors 58 can be individuallyelectrically coupled with at least one electrical load 20. For example,the third, fourth, and fifth switching modules 46, 48, 50 are each shownhaving an electrical load 20 coupled with the corresponding switchingelement 62 via a corresponding input/output connector 58. While only asingle input/output connector 58 is coupled with a subset of theswitching modules 26, non-limiting aspects of the disclosure can beincluded wherein a switching module 26 can include a set of input/outputconnectors 58, or wherein a set of electrical loads 20 are electricallycoupled with a single input/output connector 58. Stated another way, asingle switching module 26 can include a set of electrically coupledelectrical loads 20 and set of input/output connectors 58. Aspects canfurther be included wherein the switching module 26 can include aswitching element 62 corresponding to each input/output connector 58.

Aspects of the switching element 62 can include an electrical switch,such as a solid state power controller, a solid state switch, or atransistor, such as a silicon carbide (SiC) or Gallium Nitride (GaN)based, high bandwidth power switch. SiC or GaN can be selected based ontheir solid state material construction, their ability to handle largepower levels in smaller and lighter form factors, and their high speedswitching ability to perform electrical operations very quickly.Additional non-limiting examples of the switching element 62 can includenon-polar switching elements 62. Yet additional non-limiting examples ofthe solid state switch can comprise silicon-based power switches, alsocapable of high speed switching.

The electrical power interface 56 can be configured to, for example,electrically couple the switching element 62 of the respective module42, 44, 46, 48, 50, 52, 54 to the at least one input/output connector 58of the same module 42, 44, 46, 48, 50, 52, 54. Additionally, oralternatively, the electrical power interface 56 can be configured toreceive a conductor 64, such as a bus bar connector. The conductor 64can be selected to enable, for instance, an electrical connectionbetween the electrical power interface 56 of the respective module 42,44, 46, 48, 50, 52, 54 to at least one electrical power interface 56 ofanother module 42, 44, 46, 48, 50, 52, 54. For instance, as shown, oneconductor 64 electrically connects respective electrical powerinterfaces 56 between the first and second switching modules 42, 44.Likewise, another conductor 64 electrically connects respectiveelectrical power interfaces 56 between the second, third, fourth, fifth,and sixth switching modules 44, 46, 48, 50, 52. Length of the conductor64 can be selected based on the desired configuration, that is, thedesired electrical coupling of the set of modules 26. Additionally,configurations of the electrical power interfaces 56 or conductors 64can be selected wherein, for instance, the input/output connector 58 canbe electrically coupled with the respective switching element 62 with orwithout a conductor 64.

While not illustrated, aspects of the switching modules 26 canoptionally include additional power electronics components configured,for example, to provide or enable power conversion operations (e.g. ACto DC conversion, DC to AC conversion, a first DC power to a second DCpower, etc.) to selectively enable or disable the delivery of power toone or more particular electrical loads 20, depending on, for example,available power distribution supply, criticality of electrical loadfunctionality, or aircraft mode of operation, such as take-off, cruise,or ground operations.

Aspects of the power distribution node 16 or the power distributionapparatus 24 can be selectively or electrically coupled to additionalpower elements of the aircraft 10. For example, the first switchingmodule 42 is shown further electrically coupled with another powerdistribution node 16, by way of the transmission line received at aninput/output connector 58. Also shown, the seventh switching module 54can be electrical coupled with a generator 18, by way of thetransmission line 22 received at an input/output connector 58. While arespective power distribution node 16 and generator 18 are shown,aspects of the disclosure can include an input/output connector 58electrically coupled with another power distribution node 16, a set ofpower distribution nodes 16, or at least one power-supplying element,such as the generator 18, auxiliary power generator, emergency powersupply, or combination thereof.

If another power distribution node 16 or the generator 18 supplies powerto the power distribution node 16 or the power distribution apparatus24, the input/output connector 58 can be operating as an input connector58 to receive the supplied power. Conversely, if the input/outputconnector 58 is supplying power to another power distribution node 16 orto the generator 18 (e.g. for starting operations of astarter/generator), then the connector 58 is operating as an outputconnector 58 to deliver the power. Aspects of the disclosure can includeoperating the power distribution node 16, the power distributionapparatus 24, the switching element 62, or a combination thereof, suchthat the input/output connector 58 operably switches between receivinginput power or supplying output power, for example, to load or tobalance current or to provide power redundancies between power sourcesand electrical loads 20.

The common control module 30 or processor 38 can be configured tocontrol the effective operation of the power distribution node 16 orpower distribution apparatus 24. In this sense, the common controlmodule 30 or processor 38 can operably control the set of switchingmodules 26 to selectively enable or disable a supply of power totraverse a first electrical connection (i.e. a first powered or “hot”electrical power interface 56 or input connector 58), to anotherelectrical connection (i.e. the opposing electrical power interface 56or output connector 58). The common control module 30 or processor 38operably controls the set of switching modules 26 by selectivelyoperating the respective switching elements 62 by way of thecommunication interface controller 34 and communication interface 60.Aspects of the disclosure can be included wherein the processor 38 caninclude the communication interface controller 34.

The memory 40 of the common control module 30 can store a set ofoperational control profiles or programs for configuring or operatingthe power distribution node 16, the power distribution apparatus 24, ora combination thereof. The memory 40 can include random access memory(RAM), read-only memory (ROM), flash memory, or one or more differenttypes of portable electronic memory, such as discs, DVDs, CD-ROMs, etc.,or any suitable combination of these types of memory. The common controlmodule 30 or processor 38 can be operably coupled with the memory 40such that one of the common control module 30 and the memory 40 caninclude all or a portion of a computer program having an executableinstruction set for controlling the operation of the aforementionedcomponents, or a method of operating the same. The program can include acomputer program product that can include machine-readable media forcarrying or having machine-executable instructions or data structuresstored thereon. Such machine-readable media can be any available media,which can be accessed by a general purpose or special purpose computeror other machine with a processor. Generally, such a computer programcan include routines, programs, objects, components, data structures,algorithms, etc., that have the technical effect of performingparticular tasks or implement particular abstract data types.

Machine-executable instructions, associated data structures, andprograms represent examples of program code for executing the exchangeof information as disclosed herein. Machine-executable instructions caninclude, for example, instructions and data, which cause a generalpurpose computer, a special purpose computer, the common control module30, or special purpose processing machine to perform a certain functionor group of functions. In implementation, the functions can be convertedto a computer program comprising a set of executable instructions, whichcan be executed by the processor 38.

Thus, the common control module 30 or the processor 38 can be configuredto effectively control the operation of the set of modules 26 (forinstance, by way of the communication interface controller 34 or thecommunication interface 60) by independently controlling thecorresponding set of switching elements 62 of the modules 26. In thissense, the individual switching elements 62 of the set of modules 26 canindependently control enabling or disabling a power supply to thecoupled electrical load 20. An example of the aforementionedconfiguration and control can be instructive. In the illustrated exampleof the third switching module 46, if the conductor 64 extending betweenthe second, third, fourth, fifth, and sixth switching modules 44, 46,48, 50, 52 is supplying power to the third switching module 46, thatpower can be selectively supplied to the electrical load 20 by way ofthe input/output connector 58 electrically opposite the switchingelement 62. At least one of the common control module 30, the processor38, or the communication interface controller 34 operably controls theindependent operation of the switching element 62 of the third switchingmodule 46 by way of the communication interface 60. In aspects wherein aswitching module 26 includes a set of input/output connectors 58 and acorresponding set of switching elements 62, power can be independentlyor selectively supplied to the set of input/output connectors 58 byoperably controlling each corresponding switching element 62 by way ofthe communication interface 60.

As illustrated, the first and second switching modules 42, 44 havingnon-polar switching elements 62 can further be collectively operated asa bi-directional or bi-polar switch. As shown, the first switchingmodule 42 is coupled at an input/output connector 58 with a powerdistribution node 16, and the opposed (i.e. across the switching element62) electrical power interface 56 is electrically coupled with theproximate electrical power interface 56 of the second switching module44 by a conductor 64. The second switching module 44 is then configuredwith a conductor 64 in the opposed (i.e. across the switching element62) electrical power interface 56, wherein the conductor 64 is furtherelectrically coupled with a subset of the switching modules 46, 48, 50,52.

In this configuration the first and second switching modules 42, 44 canbe operated by way of the communication interface 60 to selectivelyenable or disable power coupling with another power distribution node16. In a first example, if the other power distribution node 16 issupplying power to the power distribution apparatus 24, the first andsecond switching modules 42, 44 can be operated to enable the powersupply to traverse across the switching element 62 of the firstswitching module 42, across the conductor 64 electrically coupling thefirst and second switching modules 42, 44, and across the switchingelement 62 of the second switching module 44 to effectively energize orprovide an electronic power distribution supply bus to the subset ofswitching modules 46, 48, 50. The subset of switching modules 46, 48, 50can then effectively provide the selective energizing or selective powersupplying for the set of electrical loads 20, as described herein. Inthis configuration, the power distribution apparatus 24 can selectivelydecouple the other power distribution node 16 by way of selectivelyopening either of the switching elements 62 of the first or secondswitching module 42, 44.

In the non-limiting illustrated aspect, the sixth and seventh switchingmodules 52, 54 can be similarly configured as a bi-directional orbi-polar switch to provide selective power or electrical access from thegenerator 18 to the third, fourth, and fifth switching modules 46, 48,50. It is further understood that the combination of the firstbi-directional switch (i.e. the first and second switching modules 42,44) and the second bi-directional switch (i.e. the sixth and seventhswitching modules 52, 54) can selectively pass power through the powerdistribution apparatus 24 to the other power distribution node 16 or tothe generator 18 to provide redundancy in the power distribution networkor electronic distribution bus of the aircraft 10, as explained above.

FIG. 3 illustrates a non-limiting isometric view of an aspect of thedisclosure wherein the power distribution apparatus 24 is exploded toillustrate a portion of the interconnection between the common controlmodule 30 and the set of switching modules 26. As shown, each of thecommon control module 30 and the set of switching modules 26 can includeat least one communicative bus tab 70 that extends normally from therespective module 30, 26 to be received in an correspondingcommunication bus slot (not shown) in the adjacent module 26.Collectively, the communicative bus tabs 70 operably define thecommunication interface 60, as explained above. In this sense, eachcommunication bus tab 70 and corresponding communication bus slot can beconfigured to enable communication with each of the configured modules26, 30, including transmission and receiving of data packets, datamessages, operable instructions, and the like.

As shown, the modules 26, 30 can include a set of communicative bus tabs70 (and correspondingly, communicative bus slots) to provide or define aset of communication interfaces 60, to provide redundancy in thecommunication interface 60, or wherein a first communicative interface60 provides a different functionality than the second communicativeinterface 60 (e.g. the first sends data, whereas the second returnsdata, etc.). Additional non-limiting aspects of the disclosure can beincluded wherein the communicative bus tabs 70 can be selectivelyremoved where they are unnecessary or not needed to further thecommunication interface 60 with the next adjacent module or element,such as the end plate 32.

FIG. 3 further illustrates a conductor 64 that can be configured orselected to extend between a predetermined subset of the modules 26, 30of the power distribution apparatus 24. The non-limiting illustratedaspect of FIG. 3 additionally illustrates an attachment interface 72,for example a set of attachment points, similarly located on each of themodules 26, 30. As shown, the attachment interface 72 can be size,shaped, configured, in registry, or the like, to receive a commonattachment 74, such as a rod configured to physically secure the powerdistribution apparatus 24 together.

A single common attachment 74 is illustrated for understanding, butaspects of the disclosure can include a set of common attachments 74, asneeded. For example, a set of attachments 74 can be included whereineach individual attachment physically secures a subset of at least twoadjacent modules 26, 30 together. Aspects of the disclosure can furtherbe included wherein the modules 26, 30 are configured in alternativegeometric shapes beyond square-like configurations (e.g. circular,triangular, trapezoidal, etc.). In such alternative configurations, thelocations of the attachment interface 72 or common attachments 74 can becorrespondingly located at corners, one or more axes, or positionsrelative to the geometric configuration such that the power distributionapparatus 24 can be physically secured together, as described herein.Alternative non-limiting aspects of the disclosure can be includedwherein the attachment interface 72 and common attachment 74 areconfigured with mechanical securing mechanisms, such as correspondingscrew interfaces, to enable the securing of the power distributionapparatus 24. Alternative securing mechanisms can be included. Forexample, at least one of the attachment interface 72 or the commonattachment 74 can include a locating pin for physically securingpurposes or alignment purposes, or a seal between adjacent modules 26,30.

FIG. 4 illustrates an isometric view of the assembled power distributionapparatus 24 of FIG. 3. As shown, aspects of the disclosure can have theset of switching modules 26 include corresponding printed circuit boards80, wherein the printed circuit boards 80 include, for example theswitching elements 62 and any other power electronics, as needed.

Also shown are a set of stopper elements 82 and a set of pass-throughelements 84, located in-line with and between the electrical powerinterfaces 56 of adjacent modules 26, 30. The stopper elements 82 can beconfigured to prevent a conductor 64 from passing between adjacentmodules 26, 30 while the pass-through elements 84 can be configured toenable a conductor 64 to pass between adjacent modules 26, 30. The setof stopper elements 82 and pass-through elements 84 can be selected toenable the electrical coupling of adjacent modules 26, 30 by way of theelectrical power interfaces 56, as desired. In one exampleconfiguration, the stopper element 82 can further be configured toretain, to restrain, to hold, or to prevent a conductor 64 from moving,sliding, or otherwise extending past a desired terminal end.

The illustrated aspects further illustrate that a subset of the modules26, 30 can also optionally include a set of heat dissipation elements86, including, but not limited to, thermal fins, heat pipes, and thelike. The heat dissipation elements 86 can be configured to dissipateheat generated by, for example, the printed circuit boards 80 or powerelectronics. The optional heat dissipation elements 86 can be configuredto enable cooling air or coolant to pass across the heat dissipationelements 86 as needed to enable a desired cooling process, a desiredcooling profile, or desired operating conditions.

The selectability and configurability of the aspects described hereincan define a modular power distribution apparatus 24 for distributingpower from a power source (such as the generator 18) to a set of poweroutput connectors 58 or to at least one electrical load 20 of, forexample, an aircraft 10. A known set of electrical loads 20 in a portionof an aircraft 10 can define a predetermined or desired set ofelectrical outputs 58. Knowing the desired electrical outputs 58 and aset of power supplied by the power source, a set of power distributionnodes 16, power distribution apparatus 24, switching modules 26, orcombination thereof can be selected to modify the power supplied by thepower source to the desired electrical outputs 58. In this sense, theswitching modules 26 are selectable or modular based at least in part onthe power supplied and the desired electrical output.

Moreover, the arrangement of the common control module 30 and set ofswitching modules 26, the power distribution apparatus 24, or powerdistribution node 16, can be customized by selecting a desiredarrangement of modules 26, 30 appropriate for or corresponding to thenumber of electrical loads 20, power distribution requirements, orcontrol of the power distribution network. In this sense, thearrangement modules 26, 30, power distribution apparatus 24, powerdistribution nodes 16, and the like, are selectable or modular based atleast in part on the power supplied by the power source, or thepreviously described arrangements.

FIGS. 5 and 6 illustrate another power distribution node 216 accordingto another aspect of the present disclosure. The power distribution node216 is similar to the power distribution node 16; therefore, like partswill be identified with like numerals increased by 200, with it beingunderstood that the description of the like parts of the powerdistribution node 16 applies to the power distribution node 216, unlessotherwise noted. Referring to FIG. 5, one difference is that the powerdistribution node 216 includes a voltage converter module 290, inaddition to the set of switching modules 26, 226. The voltage convertermodule 290 can similarly include two electrical power interfaces 56 thatare schematically illustrated at opposing longitudinal ends of themodule 290, and configured to receive a similar conductor 64.

The conductor 64 can be selected to enable, for instance, an electricalconnection between the electrical power interface 56 of the respectivemodule 242, 244, 46, 48, 50, 52, 54, 290 to at least one electricalpower interface 56 of another module 242, 244, 46, 48, 50, 52, 54, 290.For instance, as shown, one conductor 64 electrically connectsrespective electrical power interfaces 56 between the first and secondswitching modules 242, 244 and the voltage converter module 290.Likewise, another conductor 64 electrically connects respectiveelectrical power interfaces 56 between the second, switching module 46and the voltage converter module 290. Yet a third conductor 64electrically connects respective power interfaces 56 between the third,fourth, fifth, sixth, and seventh switching modules 46, 48, 50, 52, 54.Length of the conductor 64 can be selected based on the desiredconfiguration, that is, the desired electrical coupling of the set ofmodules 26, 226, 290.

The voltage converter module 290 can include power electronicscomponents configured, for example, to provide or enable powerconversion operations (e.g. AC to DC conversion, DC to AC conversion, afirst DC power to a second DC power, step-up conversion, step-downconversion, etc.). In one non-limiting example configuration, thevoltage converter module 290 can include a solid state power converter.In this sense, the power converter module 290 can receive a first powerprovided from, in one non-limiting example, the generator 18, by way ofthe conductors 64 and the third switching module 46, and convert it to adifferent power provided to the first and second switching modules 242,244 by way of another conductor 64. Non-limiting examples of first andsecond power or first and second power characteristics can include 28Volts DC or 270 Volts DC. In this sense, the power distribution node 216can operably provide switching operations to a first set of electricalloads 20 operating at a first power characteristic (via the third,fourth, fifth, sixth, and seventh switching modules 46, 48, 50, 52, 54),and to a second set of electrical loads 220 operating at a second powercharacteristic, different from the first power characteristic (via thefirst and second switching modules 242, 244). The operable switchingoperations can selectively enable or disable the delivery of power toone or more particular electrical loads 20, 220, depending on, forexample, available power distribution supply, criticality of electricalload functionality, or aircraft mode of operation, such as take-off,cruise, or ground operations.

Non-limiting aspects of the power distribution node 216 can be includedwherein the power distribution apparatus 224 can be selectively orelectrically coupled to additional power elements of the aircraft 10,such as another power distribution node 16, 216, set of powerdistribution nodes 16, 216, transmission line 22, or at least onepower-supplying element, such as the generator 18, auxiliary powergenerator, emergency power supply, or combination thereof.

Non-limiting aspects of the power distribution node 216 can also beincluded wherein the voltage converter module 290 is controllablyoperable in response to a control signal from the common control module30, processor 38, end module 228, communication interface 60, orcombination thereof. While the voltage converter module 290 is shownhaving approximately double the volume compared with the switchingmodules 242, 244, 46, 48, 50, 52, 54, larger or smaller, or othercomparable or relative size differences, can be included. Additionally,as illustrated, the power distribution node 216 can include a first setof switching modules 242, 244 electrically connected serially betweenthe end module 28 and the voltage converter module 290, and a second setof switching modules 46, 48, 50, 52, 54 electrically connected seriallybetween the voltage converter module 290 and the opposing end module 28.Additional non-limiting aspects of the disclosure can be includedwherein, for example, only one set of switching modules 26, 226 can beincluded on a single side of the voltage converter module 290.

FIG. 6 illustrates an isometric view of an assembled power distributionapparatus 224 similar to that described in FIG. 5. As shown, aspects ofthe disclosure can be included the set of switching modules 26, 226include corresponding printed circuit boards 80, 280, wherein theprinted circuit boards 80, 280 include, for example the switchingelements 62 and any other power electronics, as needed. The voltageconverter module 290 can also include a voltage converter circuit board292, including any power converter electronics, as needed. In yetanother aspect of the disclosure, a set of switching modules 26, 226 canbe connected serially, in parallel, or in a combination of serially andin parallel, relative to the power converter module 290.

The illustrated aspects further show that a subset of the modules 26, 30can also optionally include a set of heat dissipation elements 86,including, but not limited to, thermal fins, heat pipes, and the like.As shown, the voltage converter module 290 can extend approximatelydouble the length of the switching modules 26, 226 (e.g. in thedirection of the attachment interface 72), and can include voltageconverter heat dissipation elements 286 configured, capable of, orenabled to dissipate more heat, compared with the heat dissipationelements 86 of the switching modules 26, 226. The heat dissipationelements 86, 286 can be configured to dissipate heat generated by, forexample, the printed circuit boards 80 or voltage converter circuitboard 292. The optional heat dissipation elements 86, 286 can beconfigured to enable cooling air or coolant to pass across the heatdissipation elements 86, 286 as needed to enable a desired coolingprocess, a desired cooling profile, or desired operating conditions.

Non-limiting aspects of the disclosure can be included wherein, forinstance, redundant voltage converter modules 290 can be included in oneor more power distribution nodes 216 to account or adapt for inrush oroverload currents. In another non-limiting example aspect, the voltageconverter module 290 can be configured to selectively convert powerbi-directionally, that is, to or from either of the first or secondpower characteristics to the other characteristic. In yet anothernon-limiting aspect, the voltage converter module 290 can be operablyselected, controlled, sized, configured, or the like, to convert onekilowatt of power from the first power characteristic to the secondpower characteristic. In yet another non-limiting aspect, the quantityor amount of power conversion can be selected or controlled based on thecooling capabilities of the heat dissipation elements 286.

FIG. 7 illustrates a flow chart demonstrating a method 100 ofdistributing power in a power distribution system such as in an aircraft10. The method 100 begins by connecting at least one first end modulehaving at least one of an end module communication interface, a powersupply, or a processor to at least one switching module having aswitching module electrical power interface and having at least one of aswitching element, an input/output connector, a switching modulecommunication interface, or a bus bar connector by connecting the endmodule electrical power interface to the switching module electricalpower interface at 102. The method 100 then proceeds to connect the atleast one switching module to at least one voltage converter modulehaving a voltage converter module electrical power interface byconnecting the switching electrical power interface to voltage convertermodule electrical power interface at 104.

Next, the method 100 connects at least one second end module to the atleast one voltage converter module or at least one other switchingmodule at 106. The method 100 then includes physically attaching in oneor two axes the at least one first end module to the at least oneswitching module, and the at least one switching module to the at leastone voltage converter module, and the at least one voltage convertermodule or at least one other switching module to the at least one secondend module by way of an attachment interface on each module at 108.Finally, the method 100 connects the at least one switching module to apower source. The method can then optionally operate the common controlmodule and switching modules as described herein.

The sequence depicted is for illustrative purposes only and is not meantto limit the method 100 in any way as it is understood that the portionsof the method can proceed in a different logical order, additional orintervening portions can be included, or described portions of themethod can be divided into multiple portions, or described portions ofthe method can be omitted without detracting from the described method.For example, the connecting of the at least one switching module to atleast one other switching module at 104 can further includes selectingan order for disposition of the switching modules or solid state powercontrollers.

Many other possible aspects and configurations in addition to that shownin the above figures are contemplated by the present disclosure. Forexample, one aspect of the disclosure contemplates a configurationwherein both end modules 28 can include common control modules 30 toenable, for example, redundancy in controlling the switching modules.Additionally, any number of switching modules 26 can be included in apower distribution node 16 or a power distribution apparatus 24, and canbe arranged or assembled based on like power distribution requirementssuch as AC or DC power, like power outputs such as voltage levels,electrical load 20 criticality, load or current balancing such ascurrent draw, or the like. In another example configuration, a set orsubset of the switching modules can be electrically arranged in parallelto perform additional or alternative power distribution or switchingoperations. In yet another configuration, the input/output connectors 58can be selectively enabled or configured to only operate in one of inputor output mode. In another non-limiting aspect, one or more voltageconverter modules 290 can be directly connected with an electricaloutput or electrical load 20, 220. Similarly, in another non-limitingaspect, one or more voltage converter modules 290 can be directlyconnected with a power input, such as a generator 18.

In yet another configuration, the common control module 30 can furtherreceive instructions or control signals from additional systems,including emergency systems, aircraft control systems, fault systemidentifiers, and the like. In yet another configuration, the physicalconfiguration of the set of modules 26, 30 can be keyed or arranged suchthat the power distribution apparatus 24 can only be correctly coupled,assembled, or operated in a single known arrangement to preventincorrect assembly or operation. For example, at least one of the commonattachment 74 or the communicative bus tabs 70 can be keyed or arrangedto provide a known assembly orientation. In yet another configuration,the above-described configuration of the two switching modules 26providing the bi-directional or bi-polar switch can be substituted witha single switching module 26 configured to provide bi-directional orbi-polar switching between the power distribution node 16 or powerdistribution assembly 24 and the greater power distribution network. Inyet another aspect of the disclosure, the common control module 30 of afirst power distribution apparatus 24 can be communicatively coupledwith at least one other common control module 30 of at least anotherpower distribution apparatus 24 such that the power distribution networkcan share control, awareness, statuses, or errors across the network.

The aspects disclosed herein provide a method and apparatus fordistributing power in a power distribution network by assembling amodular and scalable power distribution and conversion apparatus. Thetechnical effect of the above-described aspects is that a modular powerdistribution node or apparatus can be designed, as needed or on-demand,to operate power switching functions to electrical loads, or powerconverting and further switching functions, as described herein. Oneadvantage that can be realized in the above aspects is that thetailoring to the particularized power distribution needs can reduce thenumber of unnecessary components included in the distribution node.Furthermore, the power distribution apparatus itself can be selected toonly provide a limited number of power outputs, including dissimilarpower output characteristics (via the power converter module) tailoredto the expected number of electrical loads required for particular nodeoperations. Thus, aspects of the disclosure enable an optimizedcomponent size and power conversion operations per node installation. Byreducing the number of components and reducing the total installationnode volume, the above-described aspects of the disclosure have superiorweight and size advantages over the conventional power distributionsystems.

Another advantage to the above-described aspects is that by reducing thenumber of unnecessary components can reduce the cost for the powerdistribution assembly or node. Moreover, a decreased number of parts asthe system will make the distribution system, power distributionapparatus, or node inherently more reliable. Yet another advantage tothe above-described aspects is that the smaller installation volume ofthe power distribution assembly can allow for the installation of theassembly closer to the electrical loads being serviced by the node. Thiscloser proximity results in a reduction of interconnecting transmissionwire lengths with the assembly output, and hence a corresponding weightreduction due to wiring. The power converting functionality can furtherallow for installation of the assembly closer to the electrical loadswithout having to include external power converting apparatus. The powerconverting functionality can further be tailored by utilizing smallerconverters in the system, to minimize over-supply at a disposedlocation, while allowing minimal cooling due to smaller powerconversion. Furthermore, by utilizing smaller converters, redundanciesin power conversion can be included with less disruption, volumerequired, or heat requirements.

Yet additional advantages can include minimized wire weight due toproximity of the power distribution node to the electrical loads,greater flexibility in design and utilization of power electronics,modular construction, and reusable modules resulting in reducedengineering, development, testing, and validation efforts and costs.

When designing aircraft components, important factors to address aresize, weight, and reliability. The above described power distributionapparatus results in a lower weight, smaller sized, increasedperformance, and increased reliability system. The lower number of partsand reduced maintenance will lead to a lower product costs and loweroperating costs. Reduced weight and size correlate to competitiveadvantages during flight.

To the extent not already described, the different features andstructures of the various aspects may be used in combination with eachother as desired. That one feature may not be illustrated in all of theaspects is not meant to be construed that it may not be, but is done forbrevity of description. Thus, the various features of the differentaspects may be mixed and matched as desired to form new aspects, whetheror not the new aspects are expressly described. All combinations orpermutations of features described herein are covered by thisdisclosure.

This written description uses examples to disclose aspects of thedisclosure, including the best mode, and also to enable any personskilled in the art to practice the disclosure, including making andusing any devices or systems and performing any incorporated methods.The patentable scope of the disclosure is defined by the claims, and mayinclude other examples that occur to those skilled in the art. Suchother examples are intended to be within the scope of the claims if theyhave structural elements that do not differ from the literal language ofthe claims, or if they include equivalent structural elements withinsubstantial differences from the literal languages of the claims.

What we claim is:
 1. A modular power distribution apparatus comprising:a first end module and a second end module, at least one of the first orsecond end modules having at least one of an end module communicationinterface, a power supply, or a processor; at least one switching modulehaving a switching module electrical power interface configured toelectrically connect to another switching module electrical powerinterface, and having at least one of a switching element, aninput/output connector, a switching module communication interface, or abus bar connector; and at least one voltage converter module having anelectrical power interface configured to electrically connect to atleast one switching module electrical power interface, another voltageconverter module electrical power interface, or a bus bar connector;wherein at least a subset of the first end module, the second endmodule, the at least one switching module, and the at least one voltageconverter module have an attachment interface configured to physicallysecure the at least one switching module and the at least one voltageconverter module to and between the first end module and the second endmodule, or to another switching module or voltage converter module, withthe at least one of the first or second end modules communicativelyconnected to the at least one switching module, and at least one of theswitching element, input/output connector, the switching modulecommunication interface, or the bus bar connector being selectivelyconnected to at least one of the first end module, the second endmodule, another switching module, or the voltage converter module. 2.The modular power distribution apparatus of claim 1, wherein the voltageconverter module is connected to the switching module communicationinterface.
 3. The modular power distribution apparatus of either ofclaim 1, wherein the attachment interface includes a set of attachmentpoints, and the set of attachment points among the first end module, thesecond end module, the at least one switching module, and the voltageconverter module are in registry.
 4. The modular power distributionapparatus of claim 1, wherein the switching element is a solid statepower controller.
 5. The modular power distribution apparatus of claim1, wherein the attachment interface includes at least one of a locatingpin or a seal.
 6. The modular power distribution apparatus of claim 1,comprising a first set of switching modules electrically connectedserially between the first end module and the voltage converter module,and a second set of switching modules electrically connected seriallybetween the voltage converter module and the second end module.
 7. Themodular power distribution apparatus of claim 6, wherein the powerconverter module is configured to convert a first power supply receivedto a second power supply.
 8. The modular power distribution apparatus ofclaim 7, wherein the first set of switching modules operably enable ordisable the first power supply and the second set of switching modulesoperably enable or disable the second power supply.
 9. The modular powerdistribution apparatus of claim 1, wherein the voltage converter moduleincludes a solid state power converter.
 10. A modular power distributionapparatus comprising: at least one first end module and at least onesecond end module, at least one of the first and second end moduleshaving at least one of an end module communication interface or aprocessor; at least one switching module having a switching moduleelectrical power interface configured to electrically connect to atleast another switching module electrical power interface, and having atleast one of a switching element, an input/output connector, a switchingmodule communication interface, or a bus bar connector; and at least onevoltage converter module having a voltage converter module electricalpower interface to connect to at least another voltage converter powerinterface, at least one switching module electrical power interface, ora bus bar connector; wherein the first end module, the second endmodule, the at least one switching module, and the at least one voltageconverter module have an attachment interface configured to physicallysecure the at least one switching module to at least one of the first orsecond end modules, between the first end module and the second endmodule, or to another switching module or voltage converter module, inone or more axes.
 11. The modular power distribution apparatus of claim10, wherein at least one of the first end modules has a communicationinterface or a processor and at least one of the second end modules is aphysical cover.
 12. The modular power distribution apparatus of eitherof claim 10, wherein the attachment interface includes a set ofattachment points, and the set of attachment points among the at leastone first end module, the at least one second end module, the at leastone switching module, and at least one voltage converter module are inregistry.
 13. The modular power distribution apparatus of claim 10,wherein the voltage converter module is solid state.
 14. The modularpower distribution apparatus of claim 10, wherein the attachmentinterface includes at least one of a locating pin or a seal.
 15. Themodular power distribution apparatus of claim 10, comprising a first setof switching modules electrically connected serially or in parallelbetween the first end module and the voltage converter module, and asecond set of switching modules electrically connected serially betweenthe voltage converter module and the second end module.
 16. The modularpower distribution apparatus of claim 15, wherein the power convertermodule is configured to convert a first power supply received to asecond power supply, and wherein the first set of switching modulesoperably enable or disable the first power supply and the second set ofswitching modules operably enable or disable the second power supply.17. A method of distributing power in an aircraft, the methodcomprising; connecting at least one first end module having at least oneof an end module communication interface, a power supply, or a processorto a at least one switching module having a switching module electricalpower interface and having at least one of a switching element, aninput/output connector, a switching module communication interface, or abus bar connector by connecting the end module communication interfaceto the switching module communication interface; connecting the at leastone voltage converter module to the at least one other switching modulehaving a voltage converter module electrical power interface byconnecting the switching electrical power interface to the voltageconverter module electrical power interface; connecting at least onesecond end module to the at least one voltage converter module or atleast one other switching module; physically attaching in one or twoaxes the at least one first end module to the at least one switchingmodule, and the at least one switching module to the at least onevoltage converter module, and the at least one voltage converter moduleor at least one other switching module to the at least one second endmodule by way of an attachment interface; and connecting the at leastone switching module to a power source.
 18. The method of claim 17,wherein the attachment interface includes a set of attachment points,and the set of attachment points among the at least one first endmodule, at least one second end module, at least one switching module,and the at least one voltage converter module are in registry.
 19. Themethod of claim 17, wherein at least one of the switching elements is asolid state power controller, and connecting the at least one switchingmodule to at least one other switching module includes selecting anorder for disposition of the solid state power controller.
 20. Themethod of claim 17, wherein connecting the at least one switching moduleto at least one other switching module includes selectively connectingone bus bar connect to another to form an electronic distribution bus.